Layered, adjustable and natural latex side-sleeper pillow

ABSTRACT

Described herein are customizable pillows and related methods of customizing for non-toxic, ergonomically correct spinal alignment and support for a human subject in a side-lying position. For example, a customizable pillow may comprise: an outer casing formed of a first textile and comprising an aperture; a plurality of layers positioned within the outer casing, wherein: each of the plurality of layers is insertable into and removable from the washable outer casing via the aperture; each of the plurality of layers has a shoulder recess to receive a portion of the subject&#39;s shoulder; each of the plurality of layers has a top surface facing toward the subject&#39;s head, a bottom surface facing away from the subject&#39;s head, and a layer height between the top and the bottom surfaces; the plurality of layers are removably arranged as a stack; each of the plurality of layers is individually encased in a layer-casing formed of a removable, washable second textile; and each of the plurality of layers comprises a natural latex.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority to U.S. Provisional Patent Application No. 62/898,206 filed Sep. 10, 2019, which is hereby incorporated by reference in its entirety.

BACKGROUND OF INVENTION

The present invention relates to a natural pillow for side-sleepers that adjusts by adding or removing layers to provide for ergonomically correct spinal alignment and comfortable support.

Sleep is a critical component of our health. Between 50-70% of adults sleep on their sides. “When you sleep on your side, your airways are left open, your head and neck are aligned, and your esophagus is slightly elevated. This all creates an atmosphere that prevents snoring, sleep apnea, and acid reflux while ensuring comfort. In fact, one of the first lines of treatment for snoring and mild cases of sleep apnea is to start sleeping on the side.” Amelia Wilson, Tuck.com 1/8/18. This pillow is sufficiently structured to provide proper spinal support, while being soft enough that it is comfortable for the user.

Many pillows on the market are adjustable by removing or adding shredded foam or other products. After applying the pressure of the head, this internal support fails, causing the spine to be out of alignment and ultimately resulting in neck pain and discomfort. The present invention is adjustable with layers that remain supportive even under the weight of the head. Because of the composition of natural latex, the layers do not compress during usage. The present invention offers each user ergonomically correct support by providing the correct vertical rise for the neck, shoulder, and spine.

The present invention is comprised of natural and organic materials. Eliminating the presence of common VOCs (Volatile Organic Compounds), the consumer will experience safer sleep. The natural latex layers relieve pressure point discomfort and are resistant to dust mites, mildew, bacteria, mold and allergens. This material is durable, responsive and does not break down like synthetic foams.

Therefore, a need exists in the field for a side sleeper pillow that is adjustable, natural, supportive, comfortable and durable.

SUMMARY OF THE INVENTION

Provided herein are customizable pillows, kits for assembling customizable pillows, and methods for assembling customizable pillows. The pillows disclosed herein provide ergonomically correct spinal alignment, such as illustrated in FIGS. 15A-15B, and support for a human subject in a side-lying position. The pillows disclosed herein are customizable to fit a variety of body types and relieve pain points, while also being free of toxic materials and chemical off-gassing. The pillows are resistant to mold, mildew, dust mites, bacteria and allergens. The natural latex composition of the pillows provides a number of functional advantages including high durability and environmental sustainability.

Aspects of the invention include a customizable pillow for providing ergonomically correct spinal alignment and support for a human subject in a side-lying position. As discussed, this is important in view of variations in individual sizes and geometries, meaning that a standard pillow is not necessarily ideal for different individuals. Pillows described herein may comprise: an outer casing (preferably, a stretchable outer casing) formed of a first textile and comprising an aperture; a plurality of layers positioned within the outer casing, wherein: each of the plurality of layers is insertable into and removable from the outer casing via the aperture; each of the plurality of layers has a shoulder recess to receive a portion of the subject's shoulder; each of the plurality of layers has a top surface facing toward the subject's head, a bottom surface facing away from the subject's head, and a layer height between the top and the bottom surfaces; the plurality of layers are removably arranged as a stack; each of the plurality of layers is individually encased in a layer-casing formed of a second textile; and each of the plurality of layers comprises a natural latex. Preferably, the layers are removably arranged as a stack along a stacking axis that is parallel to an axis corresponding to the layer height. In other words, as a layer is added, the overall pillow thickness that supports the head increases. Similarly, the layers may be provided in any number of thicknesses, so that a larger individual has an ability to select a thicker layer compared to a smaller individual. Alternatively, a smaller individual may use fewer layers. Preferably according to any embodiment of the pillows, kits and methods disclosed herein, each of the plurality of layers is formed of a natural latex. Preferably according to any embodiment of the pillows, kits and methods disclosed herein, each of the plurality of layers is entirely (≥99% by mass) formed of a natural latex.

Preferably according to any embodiment of the pillows, kits and methods disclosed herein, the plurality of layers comprises at least one thick layer having an undeformed layer height of 2±1 inches and at least one thin layer having an undeformed layer height selected from the range of 0.1 to 2 inches, wherein each thick layer has an undeformed layer height that is greater than that of each thin layer. Optionally according to any embodiment of the pillows, kits and methods disclosed herein, each of the at least one thick layer has an undeformed layer height of 2±0.5 inches, optionally 2±0.2 inches, optionally 2±0.1 inches. Optionally according to any embodiment of the pillows, kits and methods disclosed herein, each of the at least one thin layer has an undeformed layer height of 1±0.9 inches, optionally 1±0.5 inches, optionally 1±0.2 inches, optionally 1±0.1 inches. Optionally according to any embodiment of the pillows, kits and methods disclosed herein, the pillow or kit comprises one thick layer and one thin layer. Optionally according to any embodiment of the pillows, kits and methods disclosed herein, the pillow or kit comprises one thick layer and two thin layers. Optionally according to any embodiment of the pillows, kits and methods disclosed herein, the pillow or kit comprises one thick layer and three thin layers. Optionally according to any embodiment of the pillows, kits and methods disclosed herein, the pillows comprise a thick layer, according to any embodiment herein, sandwiched between two thin layers, each according to any embodiment herein. Optionally according to any embodiment of the pillows, kits and methods disclosed herein, the pillow comprises a thick layer, according to any embodiment herein, and two thin layers, each according to any embodiment herein, stacked on top of the thick layer.

Optionally according to any embodiment of the pillows, kits and methods disclosed herein, each of the plurality of layers comprises through-holes or cylindrical cavities, described as a pin-core construction. Optionally according to any embodiment of the pillows, kits and methods disclosed herein, each of the plurality of layers comprises an array, lattice, or matrix of the through-holes or cylindrical cavities. Preferably, each through-hole is a straight cylindrical cavity extending through the thickness or layer height of the respective layer. The pin-core construction provides breathability, natural cooling and a desired softness or firmness to the respective layer. The quantity, or quantity-per-area, and dimensions of cylindrical cavities or through-holes (pin-core construction) in a natural latex at least partially determine a density and/or ILD of the natural latex. A cylindrical cavity is a type of through-hole. The configuration of through-holes may be described in terms of a porosity, wherein the porosity is defined as (volume of all through-holes)/(undeformed layer volume). The desired stiffness and compressibility of the pillow can vary based on the range in porosity. Depending on the desired stiffness and compressibility of the pillow, the porosity range may be independently selected from between 0.01 to 0.2. Optionally according to any embodiment of the pillows, kits and methods disclosed herein, the natural latex is a foam. Optionally, the foam is microporous, having micropores. Any one or more of cylindrical cavities, through-holes, porosity, thickness, density or the like may be independently selected in the layers to provide a highly customizable pillow matched to a particular user.

Preferably according to any embodiment of the pillows, kits and methods disclosed herein, each of the plurality of layers is formed of an identical natural latex. Optionally according to any embodiment of the pillows, kits and methods disclosed herein, each of the plurality of layers is formed of at least two different natural latex materials (differing in densities and firmness). For example, at least one layer may have a density and/or a firmness that is at least 10% different from another layer's density and/or firmness. Alternatively, the layers may all have substantially the same density and/or firmness, including within at least 5% of each other, with at least one layer having a different undeformed thickness than another layer, including at least 10% different from each other.

Preferably according to any embodiment of the pillows, kits and methods disclosed herein, the top and bottom surfaces among the plurality of layers are equivalent or identical in shape and in surface area. In other words, preferably, a shape and a surface area of the top surface are equivalent or identical to a shape and a surface area, respectively, of the bottom surface of each of the plurality of layers; and wherein the shape and the surface area of the top and bottom surfaces of each the plurality of layers are equivalent or identical to the shape and surface area, respectively, of the top and bottom surfaces of each other layer of the plurality of layers. Optionally according to any embodiment of the pillows, kits and methods disclosed herein, the top and bottom surfaces among the plurality of layers are identical in shape and in surface area. Preferably according to any embodiment of the pillows, kits and methods disclosed herein, a top and/or bottom of the outer casing has a shape that is equivalent to the shape of the top and/or bottom of each of the plurality of layers.

Preferably according to any embodiment of the pillows, kits and methods disclosed herein, each of the plurality of layers is characterized by an indentation load deflection (ILD) selected from the range of 10-21. Optionally according to any embodiment of the pillows, kits and methods disclosed herein, each of the plurality of layers is characterized by an indentation load deflection (ILD) selected from the range of 11 to 14. Optionally according to any embodiment of the pillows, kits and methods disclosed herein, each of the plurality of layers is characterized by an indentation load deflection (ILD) selected from the range of 10-15, optionally 16-21. Optionally according to any embodiment of the pillows, kits and methods disclosed herein, each of the plurality of layers is characterized by an indentation load deflection (ILD) selected from the range of, optionally 12 to 14. Preferably according to any embodiment of the pillows, kits and methods disclosed herein, each of the plurality of layers is characterized by an ILD that is equivalent to an ILD of each other layer.

Preferably according to any embodiment of the pillows, kits and methods disclosed herein, the plurality of layers have a combined undeformed layer height of selected from the range of 1 inch to 5 inches. Optionally according to any embodiment of the pillows, kits and methods disclosed herein, the plurality of layers have a combined undeformed layer height of selected from the range of 2 inches to 5 inches.

Preferably according to any embodiment of the pillows, kits and methods disclosed herein, the outer casing comprises a shoulder recess. Preferably according to any embodiment of the pillows, kits and methods disclosed herein, a shape (when the layer is viewed along an axis perpendicular to the top or bottom surface of the respective layer) of the shoulder recess of each layer comprises a characteristic radius selected from the range of 2.5 inches to 4 inches, optionally 2.5 inches to 3.5 inches, optionally 3 inches to 4 inches. Preferably the characteristic radius is 3±0.2 inches. Optionally according to any embodiment of the pillows, kits and methods disclosed herein, a shape (when the outer casing is viewed along an axis perpendicular to the top or bottom surface of the outer casing) of the shoulder recess of the outer casing comprises a characteristic radius selected from the range of 2.5 inches to 4 inches, optionally 2.5 inches to 3.5 inches, optionally 3 inches to 4 inches. Optionally according to any embodiment of the pillows, kits and methods disclosed herein, each of the top and bottom surface of each of the plurality of layers has a surfaces area less than 360 in.²

Preferably according to any embodiment of the pillows, kits and methods disclosed herein, the outer casing comprises a zipper for opening and closing the aperture; wherein the aperture is configured such that each layer is inserted or removed from the casing along a plane parallel to the layer's top or bottom surface. Optionally according to any embodiment of the pillows, kits and methods disclosed herein, the outer casing comprises a flap to cover the aperture. Optionally according to any embodiment of the pillows, kits and methods disclosed herein, the outer casing comprises a flap and a zipper, including a flap to cover the zipper. For example, the outer casing may comprise a flap covering the aperture or zipper. Optionally according to any embodiment of the pillows, kits and methods disclosed herein, the outer casing is free of a zipper.

Preferably according to any embodiment of the pillows, kits and methods disclosed herein, each layer-casing is washable, preferably machine-washable. Optionally, according to any embodiment of the pillows, kits and methods disclosed herein, each layer is washable. Preferably according to any embodiment of the pillows, kits and methods disclosed herein, the outer casing is washable, preferably machine-washable. Preferably according to any embodiment of the pillows, kits and methods disclosed herein, the outer casing and each layer-casing is washable, preferably machine-washable. Preferably according to any embodiment of the pillows, kits and methods disclosed herein, the first textile is a natural/sustainable knit or quilted fabric. Preferably according to any embodiment of the pillows, kits and methods disclosed herein, the second textile is a breathable natural/sustainable fabric. Preferably according to any embodiment of the pillows, kits and methods disclosed herein, the outer casing and/or each layer-casing is gusseted. Preferably according to any embodiment of the pillows, kits and methods disclosed herein, the outer casing and/or each layer-casing that is thicker than one inch are gusseted The first and/or second textile may be stretchable. Preferably, both the first and second textile are stretchable. Preferably, the first textile is stretchable.

Preferably according to any embodiment of the pillows, kits and methods disclosed herein, each of the layers is not formed of a memory foam.

Aspects of the invention also include a kit for assembling a customizable pillow for providing ergonomically correct spinal alignment and support for a human subject in a side-lying position, the kit comprising: an outer casing formed of a first textile and comprising an aperture, including an outer casing that is stretchable to accommodate and reliably position a different number of layers within the outer casing; a plurality of layers positioned within the outer casing, wherein: each of the plurality of layers is insertable into and removable from the outer casing via the aperture; each of the plurality of layers has a shoulder recess to receive a portion of the subject's shoulder; each of the plurality of layers is individually encased in a layer-casing formed of a second textile; and each of the plurality of layers comprises a natural latex; and wherein upon assembly of the pillow, each inserted layer has a top surface facing toward the head of the subject, a bottom surface facing away from the head of the subject, and a layer height between the top and the bottom surfaces; and each layer is removably arranged as a stack. Preferably, the layers are removably arranged as a stack along a stacking axis that is parallel to an axis corresponding to the layer height. Optionally in any kit, the plurality of layers comprises at least one thick layer having an undeformed layer height of 2±0.5 inches and at least one thin layer having an undeformed layer height of 1±0.5 inches. (Use of “±” refers to an inclusive range of values.)

Optionally, in any kit, each of the layers is characterized by an indentation load deflection (ILD) that is different from the ILD of any of the other layers. Optionally, in any kit, the layers are characterized by an indentation load deflection (ILD) selected from the range of 10 to 21. The kit preferably includes instructions on how to customize the pillow to a user characteristic, such as a size, length or other dimension that tends to be user specific. For example, the distance between the outer shoulder and the face or neck may be matched by an appropriate selection of layer(s) to thereby provide a custom-fit pillow. In this manner, a user may specifically order one, two or three layers that provides the most comfort to the user. The one, two or three layers may be tailored to the user in terms of one or more of deformability (softness), height, density, so that the assembly of all the layers into the pillow is better matched to the user. This is advantageous over conventional “one-layer” pillows because there is no need to replace entire pillows or specially manufacture the entire pillow for each user. Use of layers in various stock sizes and characteristics that can be independently mixed and matched provide a very high degree of user-customization without unduly impacting cost.

Aspects of the inventions also include a method for assembling a customizable pillow for providing ergonomically correct spinal alignment and support for a human subject in a side-lying position, the method comprising: inserting a first thin layer into an outer casing via an aperture in the outer casing; and inserting a first thick layer into the outer casing via the aperture in the outer casing; wherein: the outer casing is formed of a first textile and comprises an aperture; each layer has a shoulder recess to receive a portion of the subject's shoulder; each layer comprises a natural latex; when the pillow is assembled, each layer has a top surface facing toward the subject's head, a bottom surface facing away from the subject's head, and a layer height between the top and the bottom surfaces; and the inserted layers in the outer casing are arranged in a stacked configuration. Preferably, the layers are removably arranged as a stack along a stacking axis that is parallel to an axis corresponding to the layer height. Preferably in any method disclosed herein, each layer is removable and replaceable with a second thin layer and/or a second thick layer to provide optimal customization. Preferably in any method disclosed herein comprises inserting a second thin layer and/or a second thick layer. Any of the methods may further comprise the step of stretching the outer casing to accommodate a layer, such as to accommodate a first layer, second layer, and/or a third layer. The stretched outer casing, after having received the layer(s), may then relax upon removal of the externally applied force that caused the initial stretching to a relaxed state. The relaxed state may be a partially relaxed state where there is residual tension applied by the outer casing on the layer(s) in the outer casing. The method may further comprise the step of customizing the pillow to a user by having the user select one or more layers depending on an appropriate height for a user-characteristic. “User-characteristic” refers to a user-dependent parameter, including one or more of a user size, weight, dimension, such as a body portion size, weight and/or dimension, including of the neck and/or shoulder. This can be reflected in a preference of pillow firmness and height that provides the most comfort to a user. For example, one, two and/or three layers may be selected to match one or more user-characteristics, including corresponding to a distance between the outer shoulder and the head or face. For example, matching or satisfying user-characteristics may correspond to selecting a total thickness of all layers of the pillow, which may depend on the firmness (e.g., ILD) of the layers. For example, a user having heavier body characteristic may elect to have more layers, thicker layer(s), higher density or stiffness in a layer(s) than a relatively smaller or lighter person.

Without wishing to be bound by any particular theory, there may be discussion herein of beliefs or understandings of underlying principles relating to the devices and methods disclosed herein. It is recognized that regardless of the ultimate correctness of any mechanistic explanation or hypothesis, an embodiment of the invention can nonetheless be operative and useful.

BRIEF DESCRIPTION OF THE DRAWINGS

Some embodiments of the present invention are illustrated as an example and are not limited by the figures of the accompanying drawings, in which like references may indicate similar elements and in which:

FIG. 1 depicts a top view of a layer of a pillow showing exemplary shape, size, and features, according to some embodiments.

FIG. 2 depicts a side view of an exemplary thin layer and exemplary dimensional ranges thereof, according to certain embodiments disclosed herein.

FIG. 3 depicts a side view of an exemplary thick layer and exemplary dimensional ranges thereof, according to certain embodiments disclosed herein.

FIG. 4 are side views of a combination of two exemplary thin layers and one exemplary thick layer, and exemplary dimension ranges thereof.

FIG. 5 shows a perspective view of an exemplary arrangement of exemplary layers of a pillow disclosed herein, according to certain embodiments.

FIG. 6 shows a perspective view of an exemplary arrangement of exemplary layers of a pillow disclosed herein, and exemplary dimensions thereof. In this manner, a wide range of pillow characteristics, such as pillow height, are obtained by selecting specific characteristics for each of the three layers.

FIG. 7 shows a perspective blown up view of an exemplary arrangement of exemplary layers in an outer casing of a pillow, including layers having through-holes or cylindrical cavities. FIG. 7 also depicts a kit, according to certain embodiments. FIG. 7 also depicts the layers being inserted into an outer casing.

FIG. 8 shows a perspective view of an exemplary pillow disclosed herein, according to certain embodiments.

FIG. 9 shows a perspective cross-sectional cut-away view of an exemplary pillow. The view illustrates an outer cover encasing a plurality of layers.

FIG. 10 is a perspective view of an outer casing having a zipper for controllable opening and closing of an enclosure for insertion and removal of layers. As illustrated, the zipper closes the enclosure, thereby reliably containing layers within the outer casing. A flap may cover the zipper to minimize unwanted zipper contact during use (see, e.g., FIG. 11).

FIG. 11 is a perspective view of an exemplary pillow disclosed herein, according to certain embodiments, comprising a flap covering the zipper.

FIG. 12 shows a perspective view of the pillow of FIG. 10 with the zipper partially open to partially open the aperture.

FIG. 13 shows a perspective view of an exemplary layer, encased by a removable, envelope closure layer-casing, according to certain embodiments.

FIG. 14 depicts a top view of a layer of a pillow showing exemplary shape, size ranges, and features.

FIGS. 15A-15B illustrate a human user using a pillow of the instant invention, which facilitates correct spinal alignment. The user of FIG. 15A has different user characteristics compared to the user of FIG. 15B. Accordingly, the pillow used by the user of FIG. 15A has at least one different layer than the pillow of FIG. 15B, thereby providing user customizability and to better facilitate correct spinal alignment for individual users. In this example the pillow of FIG. 15A has three total layers—two thin and one thick, where the pillow of FIG. 15B has two total layers—one thin and one thick. The customizability is efficient, with the subjects of FIGS. 15A-15B readily able to “share” the same layers, with the addition or removal of one or more layers as needed to provide for user customization without having to necessarily purchase an entire new pillow.

DETAILED DESCRIPTION OF THE INVENTION

In general, the terms and phrases used herein have their art-recognized meaning, which can be found by reference to standard texts, journal references and contexts known to those skilled in the art. The following definitions are provided to clarify their specific use in the context of the invention.

Generally, as used herein, the term “natural latex” has its art-recognized meaning. Preferably, natural latex, is a material of which a majority, optionally at least 85% by mass, preferably at least 90% by mass, is sustainably harvested from the juice or rubber sap of the highly renewable Havea Brasiliensis tree. As described throughout, natural latex has many beneficial properties, including but not limited to: durable, sustainable, doesn't off-gas chemicals, highly mold/mildew/dust mite resistant, anti-bacterial, anti-fungal, hypoallergenic, biodegradable, noise-reducing, naturally cooling, excellent ventilation, maximum pressure distribution and improved blood circulation, supportive, healthy microclimate, comfortable and consistent. Optionally, 100% natural latex is free from chemical dyes, pesticides, bleach, carcinogenic adhesives and chemical flame retardants. It does not contain any fillers such as clay or petrochemical products used in synthetic latex. Natural latex is harvested from sustainable sources and is manufactured without fillers, toxic additives and does not emit harmful gases or odors.

The term “undeformed layer height” refers to a layer height of a layer that is resting, undeformed or otherwise free of direct or indirect pressure from the subject or an object that deforms the layer. The layer height refers to the vertical dimension of the layer, or the dimension that is the least of the three spatial dimensions of the layer.

The term “shape” when describing a top and/or bottom surface of a layer, a pillow, or a casing refers to the shape thereof when the top and/or bottom surface of the layer, the pillow, or the casing, respectively, is viewed from or along an axis perpendicular to a plane of the top and/or bottom surface of the layer, the pillow, or the casing, respectively. For example, FIGS. 1-5 show a shape of a layer of the plurality of layers of a pillow disclosed herein, with corresponding dimensions.

Two values, such values corresponding to surface area, layer height, or ILD, are “equivalent” when the two values are within 20%, within 10%, within 5%, within 1%, or preferably equal to each other.

Each of indentation load deflection (ILD) and density is a characteristic that can quantify firmness or softness of a layer or of a piece of natural latex. ILD can be measured by indenting (or compressing) a foam sample to 25% of its original height. The amount of force (in pounds) required to indent the foam is its 25% ILD measurement. The greater the ILD, the firmer the natural latex. In general, the greater the ILD for the layer, the greater the layer density.

The term “±” refers to an inclusive range of values, such that “X±Y,” wherein each of X and Y is independently a number, refers to an inclusive range of values selected from the range of X−Y to X+Y.

In the following description, numerous specific details of the devices, device components and methods of the present invention are set forth in order to provide a thorough explanation of the precise nature of the invention. It will be apparent, however, to those of skill in the art that the invention can be practiced without these specific details.

The pillows disclosed herein address many challenges and customer pain points associated with pillows, including: pain in the shoulder, neck, jaw and/or back; positional pain during sleep (such as from a non-supportive or incorrectly sized pillow);

decreased snoring, by keeping the user positioned on their side; supporting women in the side sleeping position recommended for pregnancy; pillows that break down too quickly and don't maintain their shape; pillows that don't fit the particular body type, such as due to being too high or too low; pillows being un-washable or having un-washable covers leading to a build-up of things like mold, dust mites and bacteria; poor sleep due to pillow-induced, positional discomfort; common pillows add to the landfill because they are comprised of materials of a disposable nature; pillows comprised of toxic materials that chemically off-gas and/or non-breathable materials such as certain synthetic plastics; use of toxic fire retardants; synthetic foams and latex are made from petroleum and other toxic products; down and other high allergen materials; mold, mildew, bacteria and dust mites can grow in most other pillow materials; cycle of wasted money spent on pillows that are unsatisfactory to the consumer; pillow collapse throughout the night and pillows that are non-supportive.

The pillows disclosed herein, can have the following features, for example: 100% natural and/or organic latex; organic or natural, washable outer cover; large covered zipper opening to allow for “building and adjusting” the pillow; organic (or natural/sustainable fiber) washable inner liners for the pillow layers; envelope closure for the interior liners that allows for removal for washing or replacement if needed; natural latex durability—natural latex is considerably more durable and can last up to 10 years without breaking down or losing support; layered construction for adjustability, consistent shape, and support; a variety of combinations and permutations of layers (e.g., three layers: two 1″ layers and one 2″ layer); an additional thin or 1″ layer can be added to the pillow for larger builds and softer mattresses; custom shape with a shoulder cut out on all interior layers; cover and liners are sewn to accommodate for the custom shape; custom outer pillow cases in the shape of the pillow are available for purchase as well; individual layers can be purchased and/or replaced as needed without replacing the entire pillow; and a shape that is ideal for an ergonomically correct side sleeping position.

The pillows disclosed herein have many advantages. The pillows disclosed herein are designed to be ergonomically correct side sleeping pillows. The pillows support the cervical and upper thoracic spine for keeping proper alignment in a side-lying position, such as illustrated in FIGS. 15A-15B. These pillows support the shoulder and arm to avoid brachial plexus compression. These pillows decrease numbness, tingling and tension in the arms, shoulders, neck and chest which often results from the use of common pillows. These pillows provide an opportunity for decreased neck, shoulder and back pain. Restless sleep and wakefulness, due to discomfort, are epidemic in adult sleep today. It is estimated that 70% of the adult population are side sleepers. These pillows are adjustable with a three—four layer natural latex system. The layers hold their shape, do not break down under the pressure of the head and are consistently supportive throughout the night. Even with the structured, supportive nature, these pillows provide a comfortable sleep surface for the ear, jaw and face.

These pillows can be made from natural latex. Natural latex, and use thereof, has the following benefits: durable, sustainable, doesn't off-gas chemicals, highly mold/mildew/dust mite resistant, anti-bacterial, anti-fungal, hypoallergenic, noise-reducing, naturally cooling, excellent ventilation, maximum pressure distribution and improved blood circulation, supportive, healthy microclimate, comfortable and consistent. More particularly, benefits of the natural latex used herein (such as 100% natural latex) include being hypo-allergenic, anti-microbial, anti-bacterial, naturally cooling and biodegradable. The natural latex used herein has also been shown to support an improvement in respiratory health. The natural latex used herein provides comfort and elasticity and is extremely comfortable because it molds to the body's natural contours while maintaining high responsivity. Its extreme elasticity prevents the latex foam from packing down and compressing like synthetic foams. The natural latex used herein supports the back and spine because it holds its structure and it conforms to your body and minimizes pressure points. The natural latex used herein distributes pressure evenly providing for good circulation, healthy spinal alignment, such as illustrated by the series of circles in FIG. 15A-15B that illustrate spinal alignment for improved sleep. The natural latex used herein isolates motion and prevents disturbances from motion while sleeping. The natural latex used herein is biodegradable. The natural latex used herein can last 10 years or more. The natural latex used herein is beneficial for people who suffer from allergies.

Natural latex is a challenging material for manufacturing and is not a commonly utilized pillow material. The challenges include but are not limited to: shipping to the United States for manufacturing, as latex is grown in specific micro climates including Southeast Asia, parts of Africa and South America; fabrication—slabs of natural latex are cut into the shape of the pillow layers using a die cutting process or it is custom molded; fabrication is a limited and expensive production method domestically and globally; 100% natural latex is GOLS Certified (Global Organic Latex Standard) and FSC (Forest Management Certified) and is expensive because of the pure, high quality, natural composition; natural latex is sticky and dense in nature which makes handling, shipping and manufacturing more challenging. Due to its challenging nature for pillows and other bedding products, 100% natural latex is not commonly used in pillows. The layers disclosed herein are optionally cut from a natural latex slab or are formed by molding the carefully extracted juice of the tropical Havea Brasiliensis tree.

To the extent that natural latex is currently utilized in the pillow market, it is either molded to one, non-customizable/adjustable shape or it is shredded. Neither of those forms are ideal for supporting the user's sleep posture. The use of natural latex in removable, customizable layers is not currently found in the global pillow market.

These pillows are made from environmentally sustainable materials. The outer cover and inner liner are made from natural and organic fibers. The layers are made from 100% natural latex. Natural latex is a highly renewable resource derived from the Havea Brasiliensis tree. It can be harvested twice daily for up to 25 years (the production life of an average tree) and does not require chemical fertilizers or pesticides for the harvesting process. Natural latex is biodegradable. Because of their naturally occurring durability, these pillows are better for the environment than the average disposable pillow made of plastics and other non-biodegradable chemical materials like memory foam or synthetic latex.

These pillows are made from sustainable materials. With their durability, these pillows are better for the environment than the average disposable pillow made of plastics and other chemical materials.

The natural latex optionally has a firmness or density characterized by a 10-21 ILD which is supportive in nature while simultaneously being a soft sleep experience for the user's ear, face and jaw. In contrast, memory foam can be a very “firm” sleep experience. Natural latex is a fast response foam while memory foam and other synthetic foams are slower response. The softer, faster response foam provides for a more comfortable sleep experience.

With the adjustable layered system, these pillows work with differing mattress densities and body types.

The outer casing is made of natural and/or organic fibers with inherent cooling properties. These non-toxic materials do not produce any chemical off-gassing.

Referring to FIGS. 6-13, a pillow 100, according to certain embodiments, comprises one or more layers, such as one or more thick layers and one or more thin layers. For example, pillow 100 optionally comprises thick layer 101 and thin layers 102 and 103 (e.g., see FIGS. 6-7, etc.). Pillow 100 also comprises an outer casing 104 (e.g., see FIGS. 7, 8, 10-11, etc.). Outer casing 104 comprises an aperture 110 (e.g., see FIG. 10). Outer casing 104 optionally comprises a zipper 111 to close and open aperture 110 (e.g., see FIGS. 10-12). Outer casing 104 optionally comprises a flap 112 covering zipper 111, such as when zipper 111 is not in use. Each layer of pillow 100 is preferably encased in a layer-casing. For example, FIG. 13 is a schematic showing thin layer 102 encased in a layer-casing 106. Also disclosed herein is a kit 200 for assembling a pillow, such as pillow 100, such as kit 200 depicted in FIG. 7. FIG. 7 also illustrates through-holes or cylindrical cavities 105 in the layers, with attendant porosity as described herein. The kit (as well as related methods) may teach a user how to custom fit a pillow to the user, such as by appropriately selecting layers 101 102 103, including layer thicknesses and sizes, and thereby select appropriate outer casing 104, including size, shape and enclosure volume. For example, a user may obtain a user-specific characteristic (such as by measuring) and based on the measured user-specific characteristic, select layers and outer casing to ensure a desired custom-fit is achieved. FIGS. 1-5 illustrate some representative dimension ranges of the pillows, layers, and features thereof.

While multiple embodiments are disclosed, still other embodiments of the present invention will become apparent to those skilled in the art from this detailed description. The invention is capable of a myriad of modifications in various obvious aspects, all without departing from the spirit and scope of the present invention. Accordingly, the drawings and descriptions are to be regarded as illustrative in nature and not restrictive.

The invention can be further understood by the following non-limiting examples.

EXAMPLE 1

Provided herein is a natural, ergonomically supportive and adjustable side sleeper pillow which can be easily customized for an individual fit. Optionally, within each pillow, there are 3 removable layers of natural latex, two or three 1 inch layers and one 2 or 3 inch layer, providing a pillow height between minimum 1 and maximum 5 inches. The layers optionally have a natural latex (ILD 10-21) encased in breathable, natural fabric. All layers have a U-shaped cutout to support the shoulder and neck. The outer case is optionally an organic/natural fabric that can be removed for easy washing.

There is a horizontal zipper for access to the inner layers for washing and pillow height adjustment. The present invention provides high quality, natural, sustainable, customizable support that will last throughout the night and will remain durable over time.

The pillow is a natural, adjustable side-sleeper pillow. More particularly, the pillow is an all-natural, non-off gassing, adjustable pillow that offers correct spinal support, such as illustrated in FIGS. 15A-15B. The removable latex layers provide multiple customization options for the user. Layers can be added and removed to fit the user's body frame and mattress density.

According to certain embodiments of the present invention, the natural latex pillow comprises three distinct layers as illustrated in FIGS. 4 and 5. Each user can add or remove layers to create the desired vertical rise.

Each layer is comprised of a natural latex. Among many other attributes described herein, natural latex will not off-gas, is responsive and durable. The material also conforms to its surroundings without compressing, thereby enabling redistribution of weight and surface pressure. Such re-adjustment provides a comfortable space for the body which contributes to better overall sleep.

Each thin layer is optionally comprised of a softer (e.g., ILD 14) version of the natural latex that creates a soft, yet supportive sleeping surface. As removable inserts, they serve to provide more flexibility in determining the vertical rise of the pillow. Each layer is encased in a breathable natural/organic fabric.

Each thick layer is optionally denser (e.g., ILD 19) and provides consistent, unchanging support to the head and neck. As a removable insert, it serves to provide additional height to the pillow for people with a larger body frame. This layer is encased in a breathable natural/organic fabric.

The case that surrounds all layers of the pillow is made of natural and/or organic fabric. The all natural fiber creates a soft and healthy surface for the user with no VOCs. The case has a zipper so that layers can be added and removed. The case can be removed and washed as needed.

The pillow has a unique shoulder recess that offers proper alignment and support for side sleepers. An exemplary shoulder recess is outlined in each of FIG. 1, FIG. 14, and elsewhere.

EXAMPLE 2

The pillow of Example 2 includes: (a) one organic, washable gusseted cover with a zippered opening; (b) one 2″ natural latex layer in a washable, organic fabric liner (envelope closure); and (c) two 1″ natural latex layers in washable, organic fabric liners (envelope closure).

Each pillow has the capability to expand with an additional layer, including a 1″ layer, based on the needs of a larger framed individual. The outer cover material is made from a knit with stretch and can accommodate the extra layer. Alternatively, the outer cover material may be sufficiently sized to accommodate an additional layer without stretching. Alternatively, the outer cover may be sized and configured to undergo a combination of being sufficiently sized to partially accommodate the extra layer and to have some stretch to further accommodate the extra layer.

Preferably, each of the layers are formed of the same or equivalent natural latex.

STATEMENTS REGARDING INCORPORATION BY REFERENCE AND VARIATIONS

All references throughout this application, for example patent documents including issued or granted patents or equivalents; patent application publications, such as US 2012/0073056; and non-patent literature documents or other source material; are hereby incorporated by reference herein in their entireties, as though individually incorporated by reference, to the extent each reference is at least partially not inconsistent with the disclosure in this application (for example, a reference that is partially inconsistent is incorporated by reference except for the partially inconsistent portion of the reference).

The terms and expressions which have been employed herein are used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the invention claimed. Thus, it should be understood that although the present invention has been specifically disclosed by preferred embodiments, exemplary embodiments and optional features, modification and variation of the concepts herein disclosed may be resorted to by those skilled in the art, and that such modifications and variations are considered to be within the scope of this invention as defined by the appended claims. The specific embodiments provided herein are examples of useful embodiments of the present invention and it will be apparent to one skilled in the art that the present invention may be carried out using a large number of variations of the devices, device components, methods steps set forth in the present description. As will be obvious to one of skill in the art, methods and devices useful for the present methods can include a large number of optional composition and processing elements and steps.

As used herein and in the appended claims, the singular forms “a”, “an”, and “the” include plural reference unless the context clearly dictates otherwise. Thus, for example, reference to “a cell” includes a plurality of such cells and equivalents thereof known to those skilled in the art. As well, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein. It is also to be noted that the terms “comprising”, “including”, and “having” can be used interchangeably. The expression “of any of claims XX-YY” (wherein XX and YY refer to claim numbers) is intended to provide a multiple dependent claim in the alternative form, and in some embodiments is interchangeable with the expression “as in any one of claims XX-YY.”

When a group of substituents is disclosed herein, it is understood that all individual members of that group and all subgroups are disclosed separately. When a Markush group or other grouping is used herein, all individual members of the group and all combinations and subcombinations possible of the group are intended to be individually included in the disclosure.

Every pillow, kit, layer, combination of components, and method described or exemplified herein can be used to practice the invention, unless otherwise stated.

Whenever a range is given in the specification, for example, an ILD range a dimension range such as a thickness range, all intermediate ranges and subranges, as well as all individual values included in the ranges given are intended to be included in the disclosure. It will be understood that any subranges or individual values in a range or subrange that are included in the description herein can be excluded from the claims herein.

All patents and publications mentioned in the specification are indicative of the levels of skill of those skilled in the art to which the invention pertains. Any references cited herein are incorporated by reference herein in their entirety to indicate the state of the art as of their publication or filing date and it is intended that this information can be employed herein, if needed, to exclude specific embodiments that are in the prior art. For example, when composition of matter are claimed, it should be understood that materials or compounds known and available in the art prior to Applicant's invention, including materials or compounds for which an enabling disclosure is provided in the references cited herein, are not intended to be included in the composition of matter claims herein.

As used herein, “comprising” is synonymous with “including,” “containing,” or “characterized by,” and is inclusive or open-ended and does not exclude additional, unrecited elements or method steps. As used herein, “consisting of” excludes any element, step, or ingredient not specified in the claim element. As used herein, “consisting essentially of” does not exclude materials or steps that do not materially affect the basic and novel characteristics of the claim. In each instance herein any of the terms “comprising”, “consisting essentially of” and “consisting of” may be replaced with either of the other two terms. The invention illustratively described herein suitably may be practiced in the absence of any element or elements, limitation or limitations which is not specifically disclosed herein.

The terms and expressions which have been employed are used as terms of description and not of limitation, and there is no intention that in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the invention claimed. Thus, it should be understood that although the present invention has been specifically disclosed by preferred embodiments and optional features, modification and variation of the concepts herein disclosed may be resorted to by those skilled in the art, and that such modifications and variations are considered to be within the scope of this invention as defined by the appended claims.

The term “and/or” is used herein, in the description and in the claims, to refer to a single element alone or any combination of elements from the list in which the term and/or appears. In other words, a listing of two or more elements having the term “and/or” is intended to cover embodiments having any of the individual elements alone or having any combination of the listed elements. For example, the phrase “element A and/or element B” is intended to cover embodiments having element A alone, having element B alone, or having both elements A and B taken together. For example, the phrase “element A, element B, and/or element C” is intended to cover embodiments having element A alone, having element B alone, having element C alone, having elements A and B taken together, having elements A and C taken together, having elements B and C taken together, or having elements A, B, and C taken together. 

We claim:
 1. A customizable pillow for providing ergonomically correct spinal alignment and a supportive sleeping position for a human subject in a side-lying position, comprising: an outer casing formed of a first textile and comprising an aperture; a plurality of layers positioned within the outer casing, wherein: each of the plurality of layers is insertable into and removable from the outer casing via the aperture; each of the plurality of layers has a shoulder recess to receive a portion of the subject's shoulder; each of the plurality of layers has a top surface facing toward the subject's head, a bottom surface facing away from the subject's head, and a layer height between the top and the bottom surfaces; the plurality of layers are removably arranged as a stack; each of the plurality of layers is individually encased in a layer-casing formed of a second textile; and each of the plurality of layers comprises a natural latex.
 2. The pillow of claim 1, wherein the plurality of layers comprises at least one thick layer having an undeformed layer height of 2±1 inches and at least one thin layer having an undeformed layer height selected from the range of 0.1 to 2 inches, wherein each thick layer has an undeformed layer height that is greater than that of each thin layer.
 3. The pillow of claim 1, wherein each of the plurality of layers is formed of an identical natural latex or is formed of natural latex having a density and a firmness that is different from at least one other layer.
 4. The pillow of claim 1, wherein the top and bottom surfaces among the plurality of layers are equivalent in shape and in surface area.
 5. The pillow of claim 1, wherein each the plurality of layers is characterized by an indentation load deflection (ILD) selected from the range of 10-21.
 6. The pillow of claim 1, wherein each the plurality of layers is characterized by an ILD that is equivalent to an ILD of each other layer.
 7. The pillow of claim 1, wherein the plurality of layers have a combined undeformed layer height selected from the range of 1 inch to 5 inches.
 8. The pillow of claim 1, wherein the outer casing comprises a shoulder recess.
 9. The pillow of claim 1, wherein a shape of the shoulder recess comprises a characteristic radius selected from the range of 2.5 inches to 4 inches.
 10. The pillow of claim 1, wherein the outer casing comprises a zipper for opening and closing the aperture; wherein the aperture is configured such that each layer is inserted or removed from the casing along a plane parallel to the layer's top or bottom surface.
 11. The pillow of claim 10, wherein the outer casing comprises a flap to cover the zipper.
 12. The pillow of claim 1, wherein the outer casing and each layer-casing are removable and washable.
 13. The pillow of claim 1, wherein the first textile is a stretchable natural and/or organic fabric.
 14. The pillow of claim 1, wherein the second textile is a breathable natural and/or organic fabric.
 15. The pillow of claim 1, wherein the outer casing and/or at least one layer-casing is gusseted.
 16. The pillow of claim 1, wherein at least one of the plurality of layers comprises through-holes.
 17. A kit for assembling a customizable pillow for providing ergonomically correct spinal alignment and support for a human subject in a side-lying position, the kit comprising: an outer casing formed of a first textile and comprising an aperture; a plurality of layers positioned within the outer casing, wherein: each of the plurality of layers is insertable into and removable from the outer casing via the aperture; each of the plurality of layers has a shoulder recess to receive a portion of the subject's shoulder; each of the plurality of layers is individually encased in a layer-casing formed of a second textile; and each of the plurality of layers comprises a natural latex; and wherein upon assembly of the pillow, each inserted layer has a top surface facing toward a head of the subject, a bottom surface facing away from the head of the subject, and a layer height between the top and the bottom surfaces; and each layer is removably arranged as a stack.
 18. The kit of claim 17, wherein the plurality of layers comprises at least one thick layer having an undeformed layer height selected from the range of 1 inch to 3 inches and at least one thin layer having an undeformed layer height selected from the range of 0.1 to 2 inches.
 19. The kit of claim 18, wherein each of the at least one thick layer is characterized an indentation load deflection (ILD) that is different from an ILD of each of the at least one thin layer.
 20. A method for assembling a customizable pillow for providing ergonomically correct spinal alignment and support for a human subject in a side-lying position, the method comprising: inserting a first thin layer into an outer casing via an aperture in the outer casing; and inserting a first thick layer into the outer casing via the aperture in the outer casing; wherein: the outer casing is formed of a first textile and comprises an aperture; each layer has a shoulder recess to receive a portion of the subject's shoulder; each layer comprises a natural latex; when the pillow is assembled, each layer has a top surface facing toward the subject's head, a bottom surface facing away from the subject's head, and a layer height between the top and the bottom surfaces; and the inserted layers in the outer casing are arranged in a stacked configuration. 